still having a problem with two files that fail to start unless in safe mode, then I get a dialog about tracks assigned to a silent hardware output.  

Wasn't that fixed in X1?  Is the fix still editing the cakewalk.ini file to stop the notice.  Is this related to the file failing to load in X2?

I reassigned all outputs, sends... but no change.

Maarkr


still having a problem with two files that fail to start unless in safe mode, then I get a dialog about tracks assigned to a silent hardware output.  

Wasn't that fixed in X1?  Is the fix still editing the cakewalk.ini file to stop the notice.  Is this related to the file failing to load in X2?

I reassigned all outputs, sends... but no change.

Most of the time, if you can get a project to start only in Safe Mode it means there is a driver problem, or perhaps an FX issue. The reason you get a silent hardware output warning is because safe mode has disabled your audio drivers. (Most likely) So the project opens, but with no audio.
Good news is that it is probably not a plug, but an issue with your audio device drivers. 
Update your drivers and see what happens!
 
Brian

Saffire Pro 24 with ver 3.0 

it's only one or two tracks that show it on startup in safe mode, usually using Amplitube in a guitar track... they updated Amp 3 to ver 3.9 this week so I'm installing that later.

Double check all your sends again ... I had this problem when I had a couple of sends that were routed to MIDI hardware that no longer existed, or had changed.  I didn't even know the sends were there ... I went to Console view and checked every track.  Good luck!

SOLVED

I noticed in the console view, the track send was not grayed out even though -NONE- is selected.  This was also true on my master.  After selecting the track send options, I noticed at the bottom was -delete send-.  This still did not resolve it UNTIL I went to the Master track and selected -delete send- then did the same on the problem track.  I don't know how the option ever got changed on the master, but it was an old project that I decided to resurrect, so who knows?

"Maarkr"
I noticed in the console view, the track send was not grayed out even though -NONE- is selected.

Well call me Suzie and slap me silly..., I got caught with the same thing quite a while ago and hadn't noticed the "Delete Send" option in the second pull-down menu. The location of the "Delete Send" option is not intuitive if you ask me though, but c'est la vie.